development of an elevated flare tip to ease 40 cfr … · regulation is not the only driver for...

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Development of an Elevated Flare Tip to Ease 40 CFR 63.670 Compliance

Matthew Martin

Senior Product Line Manage

Honeywell Fellow

April 3, 2018 4C HSE CONFERENCE 2018 San Antonio, TX

UOP 8133-0

40 CFR 63.670 Major Requirements

Item Requirement Deviation Proof

PilotsAt least one pilot flame

at all timesOne minute of no pilot flame

during a 15-minute blockContinuous monitoring

SmokeLess than 5 minutes within

2 hours when less than smokeless capacity

Greater than 5 minuts of smoke over 2 hours when

less than smokeless capacity

Visual check or video monitoring

Exit Velocity

Less than 60 ft/s or less than Vmax and less than 400 ft/s when less than

smokeless capacity

Greater than the applicable velocity criteria

Calculation and vent gas measurement

Net Heating Value of Combustion Zone

(NHVcz)

Greater than or Equal to 270 Bu/SCF

Less than 270 Btu/SCF on average of a 15 minute

block duration

Calculation and monitors

Air Dilution Operating Limits

(NHVdil)

Greater than or Equal to 22 Btu/ft2

Less than 22 Btu/ft2 on average of a 15 minute

block duration


Operation Above Smokeless Capacity

Multiple Including FGRS and Co-Generation / CHP

Inability to always operate below smokeless rate

Calculation

1

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-1








Greater than 5 minutes of smoke over 2 hours when



Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

2

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-2











Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

3

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-3











Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

4

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-4











Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

5

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-5











Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

6

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

NHVdil

6 Capacity

5

UOP 8133-6











Exit Velocity


smokeless capacity




(NHVcz)



block duration



(NHVdil)



block duration





Calculation

7

1

2

3

4

5

6

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-7

Elevated Flare Tip Requirements

• Refiners and Petrochemical plants that need replacement flare tips either need or

pre-emptively want to comply with 40 CFR 63.670

• The new requirements make standby steam usage significantly more costly

8

Lower Chance of Violating NHVcz

Lower Chance of Violating NHVdil

Higher Chance of Visible Emissions

Lower Supplement Gas Requirement

Reduced Tip Life (?)

Higher Purge Gas Requirement (?)

Higher Chance of Violating NHVcz

Higher Chance of Violating NHVdil

Lower Chance of Visible Emissions

Higher Supplement Gas Requirement

Increased Tip Life (?)

Lower Purge Gas Requirement (?)

Less Noise (?) More Noise (?)

2

4

5

2

4

5

More SteamLess Steam

UOP 8133-8

Elevated Flare Tip Requirements

Regulation is Not the Only Driver for Flare Design

9

Flare Tip Quality Good Practice Driven by Regulation

Increased Smokeless Capacity X

No Smoke Under Normal Operation X X

Increased Tip Life Expectancy X

Low Standby Steam X X

Low Noise X

High Stability Flame X

Low Purge Requirement X

Well Characterized Operation X X

10

Regulations Good

Practices

Balancing

&

UOP 8133-10

The nViro-XSR

11

Patent Pending

UOP 8133-11

50ft

100ft

150ft

250ft

300ft

350ft

200ft

Introducing the nViro-XSR

Easier to Operate | Easier to Install | Lower Utility Cost

12

Superior Steam Requirements

Single Steam Connection

No Additional Muffler

RequirementLow Operating Temperature Tip

High Stability Flame

Increased Hydraulic Capacity

No Premix Air

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

2 4 5 6

6

5

.0 M

.1 M

.2 M

.3 M

.4 M

.5 M

.6 M

.7 M

nViro-XSR Other Inner Steam Upper Steam

Op

era

tin

g C

os

t (M

illio

ns

US

D/Y

ea

r)Five-Year OPEX Comparison

Smoke Suppressing Steam [$/yr]

Standby Steam [$/yr]

Purge Gas [$/yr]

Makeup Gas [$/yr]

Visible Emissions Violations [$/yr]

nViro-XSR: Reduced Operating Cost

A Flare Tip with an ROI

13

Note: Based on average flaring behavior of 2005-2015 SCAQMD refineries with 2 flares assumed and optimal flare selection. OPEX is per flare.

Standby steam rate for ‘Competitor’ is assumed based on general practice.

Product Comparison Matrix

14

Feature nViro-XSR API 521 Average

Steam-to-Hydrocarbon Ratio (Propane) 0.18 0.30

Steam-to-Hydrocarbon Ratio (Propylene) 0.20 0.55

Vent Gas Flow at Smokeless Maximum / Maximum Flow (Propane) 37% 22% *

Vent Gas Flow at Smokeless Maximum / Maximum Flow (Propylene) 33% 12% *

Minimum Keep Cool Steam (lb/hr) 0 N/A

Minimum Keep Warm Steam (lb/hr) 30 N/A

Maximum Rate Steam Noise @ 500 ft w/out Muffler 83 N/A

Standby Rate Steam Noise @ 500 ft w/out Muffler 77 N/A

Demonstrated Maximum Smokeless Rate in Test (Propane lb/hr) 216,000 N/A

Demonstrated Maximum Smokeless Rate in Test (Propylene lb/hr) 137,000 N/A

Nominal Size of Demonstration Tip 24 N/A

*Publicly published S/HC ratios. Smokeless maximum is based on ratio of S/HC to the nViro-XSR.

Note: Smokeless maximum based on a 5 Psig back pressure limit.

UOP 8133-14

Steam/Hydrocarbon Ratio - Propane

15

• Moderate-high wind

• 28,062 lb/hr steam

• 155,797 lb/hr vent gas

• 0.18 S/HC ratio

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

UOP 8133-15

Steam/Hydrocarbon Ratio - Propylene

161 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

• Moderate-high wind

• 27,575 lb/hr steam

• 136,836 lb/hr vent gas

• 0.20 S/HC ratio

UOP 8133-16

Standby Steam

• 90% reduction in steam usage compared

with previous generation

• Unique design uses the vent gas to

moderate the steam-line temperature

Keep Cool Steam Not Required | Ultra-Low Standby Steam

171 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Metal Temperature vs Wind Speed, Purge Gas Flow Rate

High

Medium

Low

Win

d S

pe

ed

Low Medium High

Purge Gas Flow Rate

Temperature

Low

High

Noise

Low Noise | Integrated Muffler

Vent GasVent Gas Flow Rate

[lb/hr]

Steam Flow Rate

[lb/hr]

Noise (dBA) @

500 ft

None 0 15,403 74

None 0 27,890 83

Propane 83,352 14,369 88

Propane 197,283 26,547 94

Propylene 50,507 15,676 89

Propylene 53,895 15,404 91

181 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Flame Stability Analysis

Stable Flame Over a Wide Operating Envelope

19

0

10

20

30

40

50

60

70

80

90

100

0 2000 4000 6000 8000 10000 12000 14000 16000 18000

No

ise L

evel

(dB

A)

Frequency

Noise Level vs Frequency (dBA)

Vent Gas Flow 161 klb/hr Vent Gas Flow 132 klb/hr Vent Gas Flow 83 klb/hr Vent Gas Flow 197 klb/hr

Vent Gas Flow 164 klb/hr Vent Gas Flow 54 klb/hr Vent Gas Flow 51 klb/hr Vent Gas Flow 143 klb/hr

Vent Gas Flow 156 klb/hr Vent Gas Flow 137 klb/hr Vent Gas Flow 105 klb/hr

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Scaling

Available in Nominal Sizes 24” to 60”

20

Available Sizes

Smallest

Mid-Size

Large

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Increased Hydraulic Capacity

• The flare tip discharge coefficient reduces

as the steam flow rate increases

• The result is more vent gas capacity with

a lower back-pressure compared to a

fixed orifice

Lower Discharge Coefficient at Higher Flow Rates

21

0 50000 100000 150000 200000 250000

Tip Efficiency vs Flow Rate

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Summary

The nViro-XSR:

• Extensively tested

• Designed to comply with 40 CFR 63.670

• 0.18 S/HC burning propane vent gas

• 0.20 S/HC burning propylene vent gas

• 37% smokeless capacity for propane

• 33% smokeless capacity for propylene

• Low noise with little noise below 500 Hz

• Integrated muffler design

• Low standby steam proven with thermocouple data and analysis

• Increase flow with unique hydraulic capacity increase

• Potentially reduce OPEX 3.6 – 24x vs other technology

22

UOP 8133-22

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

Summary

23

.0 M

.1 M

.2 M

.3 M

.4 M

.5 M

.6 M

.7 M

nViro-XSR Other Inner Steam Upper Steam

Op

era

tin

g C

os

t (M

illio

ns

US

D/Y

ea

r)

Five-Year OPEX Comparison

Smoke Suppressing Steam [$/yr]

Standby Steam [$/yr]

Purge Gas [$/yr]

Makeup Gas [$/yr]

Visible Emissions Violations [$/yr]

UOP 8133-23

1 Pilots

2 Smoke

3 Velocity

4 NHVcz

5 NHVdil

6 Capacity

development of an elevated flare tip to ease 40 cfr … · regulation is not the only driver for...

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